s80 replace shift solenoid

Solenoid for shifting 1Solenoid for shifting 1Solenoid for shifting 1Solenoid for shifting 1––––2 and 32 and 32 and 32 and 3––––4, replace4, replace4, replace4, replace Side cover, gearbox, removingSide cover, gearbox, removingSide cover, gearbox, removingSide cover, gearbox, removing See Removing gearbox side coverRemoving gearbox side coverRemoving gearbox side coverRemoving gearbox side cover Removing solenoid S1Removing solenoid S1Removing solenoid S1Removing solenoid S1

Remove: the connector the spring clamp. Pull it straight out. Use a small screwdriver the solenoid. Use a screwdriver. Insert it between the solenoid and the housing. Pry carefully. Pull the solenoid at the same time.

Check that the O-ring remains on the solenoid.

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Installing solenoid S1Installing solenoid S1Installing solenoid S1Installing solenoid S1

Apply a little petroleum jelly to the solenoid O-ring. Install:

the solenoid. Press the solenoid. Guide it in so that the locating pin on the side locates in the cut-out the spring clamp (check that it is locked) the connector.

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Installing the side cover on the gearboxInstalling the side cover on the gearboxInstalling the side cover on the gearboxInstalling the side cover on the gearbox See Installing the gearbox side coverInstalling the gearbox side coverInstalling the gearbox side coverInstalling the gearbox side cover

of 1"VCC-140174 EN 2010-10-24"

24/10/2010file://C:\Info\vv132007\ie\en\20\vcc-140174.htm

Solenoid for shifting 2Solenoid for shifting 2Solenoid for shifting 2Solenoid for shifting 2––––3, replace3, replace3, replace3, replace Side cover, gearbox, removingSide cover, gearbox, removingSide cover, gearbox, removingSide cover, gearbox, removing See Removing gearbox side coverRemoving gearbox side coverRemoving gearbox side coverRemoving gearbox side cover Removing solenoid S2Removing solenoid S2Removing solenoid S2Removing solenoid S2

Remove: the connector the spring clamp. Pull it straight out. Use a small screwdriver the solenoid. Use a screwdriver. Insert it between the solenoid and the housing. Pry carefully. Pull the solenoid at the same time.

Check that the O-ring remains on the solenoid

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Installing solenoid S2Installing solenoid S2Installing solenoid S2Installing solenoid S2

Apply a little petroleum jelly to the solenoid O-ring. Install:

the solenoid. Press the solenoid. Guide it in so that the locating pin on the side locates in the cut-out the spring clamp (check that it is locked) the connector.

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Installing the side cover on the gearboxInstalling the side cover on the gearboxInstalling the side cover on the gearboxInstalling the side cover on the gearbox See Installing the gearbox side coverInstalling the gearbox side coverInstalling the gearbox side coverInstalling the gearbox side cover

Page 1 of 1"VCC-140174 EN 2010-10-24"


Removing gearbox side coverRemoving gearbox side coverRemoving gearbox side coverRemoving gearbox side cover Special tools: 998 5972998 5972998 5972998 5972 , 999 5460999 5460999 5460999 5460 , 999 5716999 5716999 5716999 5716 , 999 5736999 5736999 5736999 5736 , 999 5972999 5972999 5972999 5972

Note! Note! Note! Note! As the illustrations in this service As the illustrations in this service As the illustrations in this service As the illustrations in this service information are used for different model years information are used for different model years information are used for different model years information are used for different model years and / or models, some variation may occur. and / or models, some variation may occur. and / or models, some variation may occur. and / or models, some variation may occur. However, the essential information is always However, the essential information is always However, the essential information is always However, the essential information is always correct.correct.correct.correct. Disconnecting the battery leadDisconnecting the battery leadDisconnecting the battery leadDisconnecting the battery lead See Note when disconnecting/connecting the Note when disconnecting/connecting the Note when disconnecting/connecting the Note when disconnecting/connecting the battery leadbattery leadbattery leadbattery lead . It is essential that the instructions are followed. Removing engine compartment componentsRemoving engine compartment componentsRemoving engine compartment componentsRemoving engine compartment components

Removing the air cleaner (ACL) housingRemoving the air cleaner (ACL) housingRemoving the air cleaner (ACL) housingRemoving the air cleaner (ACL) housing Brake pipe master cylinder / ABS unit, Brake pipe master cylinder / ABS unit, Brake pipe master cylinder / ABS unit, Brake pipe master cylinder / ABS unit, replacingreplacingreplacingreplacing . Applies only to turbocharged carsApplies only to turbocharged carsApplies only to turbocharged carsApplies only to turbocharged cars Carefully heat around the pipe at the charge air cooler (CAC). Use a hot air gun. Loosen and remove the pipe.

Removing the upper torque rodRemoving the upper torque rodRemoving the upper torque rodRemoving the upper torque rod

Remove: the plastic covers over the spring strut mountings (applies only to early versions) the screws the screw and nut for the engine mounting.

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Collecting gearbox fluidCollecting gearbox fluidCollecting gearbox fluidCollecting gearbox fluid

Use an oil suction unit. Remove the dip stick. Extract all the fluid (6 litres). This is done to avoid oil spillage when the cover is removed.

Removing the charge air pipe and hoseRemoving the charge air pipe and hoseRemoving the charge air pipe and hoseRemoving the charge air pipe and hose

Page 1 of 6"VCC-118836 EN 2010-10-24"


Remove the charge air pipe and the cooler hoses according to Gearbox, removingGearbox, removingGearbox, removingGearbox, removing . Removing the spark plugs coverRemoving the spark plugs coverRemoving the spark plugs coverRemoving the spark plugs cover Remove the spark plug cover according to Gearbox, removingGearbox, removingGearbox, removingGearbox, removing . Installing lifting fixtureInstalling lifting fixtureInstalling lifting fixtureInstalling lifting fixture

Remove the 2 screws at the engine mounting. Install lifting lug 999 5717999 5717999 5717999 5717 . Disconnect the ground strip.

Removing the connector from the gearboxRemoving the connector from the gearboxRemoving the connector from the gearboxRemoving the connector from the gearbox

Remove: the screw for the clamp holding the positive cable on the engine the connector from the gearbox (press the connector together). Pull it from the gearbox.

Remove the cable from its clips on the side member.

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Installing the lifting beam and lifting hook on Installing the lifting beam and lifting hook on Installing the lifting beam and lifting hook on Installing the lifting beam and lifting hook on the engine lifting eyelet the engine lifting eyelet the engine lifting eyelet the engine lifting eyelet Install the lifting beam and the lifting hook on the engine lifting lugs. See Gearbox, Gearbox, Gearbox, Gearbox, removingremovingremovingremoving . Disconnecting the front suspension Disconnecting the front suspension Disconnecting the front suspension Disconnecting the front suspension componentscomponentscomponentscomponents Remove the front end components according to Gearbox, removingGearbox, removingGearbox, removingGearbox, removing . Removing the screws from the cable conduit Removing the screws from the cable conduit Removing the screws from the cable conduit Removing the screws from the cable conduit and the parking heater. Removing the ground and the parking heater. Removing the ground and the parking heater. Removing the ground and the parking heater. Removing the ground lead bracket from the sublead bracket from the sublead bracket from the sublead bracket from the sub----frameframeframeframe Remove:

the screw for the front engine pad (see the arrow) the screws for the torque rod in the gearbox.

Applies only to cars with parking heaters:Applies only to cars with parking heaters:Applies only to cars with parking heaters:Applies only to cars with parking heaters:

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Page 2 of 6"VCC-118836 EN 2010-10-24"


Remove the fuel line from its clips on the sub-frame. Hang up the parking heater in a tie strap.

Removing the ball joint nut (left hand side)Removing the ball joint nut (left hand side)Removing the ball joint nut (left hand side)Removing the ball joint nut (left hand side) Remove the ball joint nut (left hand side) according to Gearbox, removingGearbox, removingGearbox, removingGearbox, removing . Removing the control arms for the antiRemoving the control arms for the antiRemoving the control arms for the antiRemoving the control arms for the anti----roll bar, roll bar, roll bar, roll bar, the track rod and the screw from the drive shaft the track rod and the screw from the drive shaft the track rod and the screw from the drive shaft the track rod and the screw from the drive shaft on the left hand sideon the left hand sideon the left hand sideon the left hand side Only slacken off the brake pipe bracket on the left-hand side. Remove the control arms for the anti-roll bar, the track rod and the screw from the drive shaft on both sides according to Gearbox, Gearbox, Gearbox, Gearbox, removingremovingremovingremoving . Removing the screws from the subRemoving the screws from the subRemoving the screws from the subRemoving the screws from the sub----frame frame frame frame support plates (both sides)support plates (both sides)support plates (both sides)support plates (both sides) Remove the screws from the sub-frame support plates (both sides) according to Gearbox, removingGearbox, removingGearbox, removingGearbox, removing . Removing the pipe lines from the subRemoving the pipe lines from the subRemoving the pipe lines from the subRemoving the pipe lines from the sub----frameframeframeframe

Unhook the servo pipe and the evaporator pipe from the holders on the right-hand side of the sub-frame. Unhook the servo pipe from the clip on the sub-frame.

Removing the stub axle from the control armRemoving the stub axle from the control armRemoving the stub axle from the control armRemoving the stub axle from the control arm Remove the stub axle from the control arm according to Gearbox, removingGearbox, removingGearbox, removingGearbox, removing . Pressing up the subPressing up the subPressing up the subPressing up the sub----frame on the rightframe on the rightframe on the rightframe on the right----hand hand hand hand sidesidesideside Press up the sub-frame on the right-hand side according to Gearbox, removingGearbox, removingGearbox, removingGearbox, removing .

Page 3 of 6"VCC-118836 EN 2010-10-24"


Removing the front cross memberRemoving the front cross memberRemoving the front cross memberRemoving the front cross member Remove the front cross member according to Gearbox, removingGearbox, removingGearbox, removingGearbox, removing . Removing the bracket for the heated oxygen Removing the bracket for the heated oxygen Removing the bracket for the heated oxygen Removing the bracket for the heated oxygen sensor (HO2S) wiringsensor (HO2S) wiringsensor (HO2S) wiringsensor (HO2S) wiring

Remove the screws for the bracket in the sub-frame holding the heated oxygen sensor (HO2S) cable. Push the bracket to one side.

Preparatory work for removing the stub axle on Preparatory work for removing the stub axle on Preparatory work for removing the stub axle on Preparatory work for removing the stub axle on the leftthe leftthe leftthe left----hand sidehand sidehand sidehand side Preparations, see Gearbox, removingGearbox, removingGearbox, removingGearbox, removing . Removing the drive shaft from the stub axle Removing the drive shaft from the stub axle Removing the drive shaft from the stub axle Removing the drive shaft from the stub axle (left(left(left(left----hand side) hand side) hand side) hand side) Remove the drive shaft from the stub axle. See Gearbox, removingGearbox, removingGearbox, removingGearbox, removing . Removing the left drive shaft from the gearboxRemoving the left drive shaft from the gearboxRemoving the left drive shaft from the gearboxRemoving the left drive shaft from the gearbox

Use 2 gimmy bars999 5736999 5736999 5736999 5736 . Note! Note! Note! Note! Do not damage the seal.Do not damage the seal.Do not damage the seal.Do not damage the seal. Note! Note! Note! Note! Do not under any circumstancesDo not under any circumstancesDo not under any circumstancesDo not under any circumstances pull the pull the pull the pull the drive shaft in such a way that could cause the drive shaft in such a way that could cause the drive shaft in such a way that could cause the drive shaft in such a way that could cause the joints to separate. The joints do not have axial joints to separate. The joints do not have axial joints to separate. The joints do not have axial joints to separate. The joints do not have axial pinions.pinions.pinions.pinions.

Removing the nuts and screws for the steering Removing the nuts and screws for the steering Removing the nuts and screws for the steering Removing the nuts and screws for the steering gear subgear subgear subgear sub----frame frame frame frame Remove the nuts and screws according to Gearbox, removingGearbox, removingGearbox, removingGearbox, removing . Removing the collision protection system over Removing the collision protection system over Removing the collision protection system over Removing the collision protection system over the steering gearthe steering gearthe steering gearthe steering gear Applies only to rightApplies only to rightApplies only to rightApplies only to right----hand drive carshand drive carshand drive carshand drive cars Remove the collision protection system according to Gearbox, removingGearbox, removingGearbox, removingGearbox, removing . Lowering the subLowering the subLowering the subLowering the sub----frameframeframeframe

Page 4 of 6"VCC-118836 EN 2010-10-24"


Use the mobile jack. Lower the sub-frame approximately 5 cm. Hang up the steering gear in a tie strap. Carefully lower the sub-frame. Let it hang free. Note! Note! Note! Note! Ensure that the screws for the steering Ensure that the screws for the steering Ensure that the screws for the steering Ensure that the screws for the steering gear release from the frame.gear release from the frame.gear release from the frame.gear release from the frame.

Removing the screw for the rear engine Removing the screw for the rear engine Removing the screw for the rear engine Removing the screw for the rear engine mountingmountingmountingmounting Remove the screw for the rear engine pad according to Gearbox, removingGearbox, removingGearbox, removingGearbox, removing . Removing the rear engine mountingRemoving the rear engine mountingRemoving the rear engine mountingRemoving the rear engine mounting Remove the rear engine mounting according to Gearbox, removingGearbox, removingGearbox, removingGearbox, removing . Preparations for removal of the gearbox side Preparations for removal of the gearbox side Preparations for removal of the gearbox side Preparations for removal of the gearbox side plateplateplateplate

Preparatory work can be carried out when the vehicle is lowered. Remove the 2 nuts from the wing liner. Angle out and tie up the wing liner to the lifting beam. Use a retaining strap. Note! Note! Note! Note! Do not damage the front wing.Do not damage the front wing.Do not damage the front wing.Do not damage the front wing.

Removing the oil pipes from the gearboxRemoving the oil pipes from the gearboxRemoving the oil pipes from the gearboxRemoving the oil pipes from the gearbox Remove the oil pipes according to Gearbox, Gearbox, Gearbox, Gearbox, removingremovingremovingremoving . Lowering the engine and gearboxLowering the engine and gearboxLowering the engine and gearboxLowering the engine and gearbox Caution! Caution! Caution! Caution! Do not damage the exhaust boots.Do not damage the exhaust boots.Do not damage the exhaust boots.Do not damage the exhaust boots. Lower the engine and gearbox according to Gearbox, removingGearbox, removingGearbox, removingGearbox, removing . Preparations for removal of the gearbox side Preparations for removal of the gearbox side Preparations for removal of the gearbox side Preparations for removal of the gearbox side covercovercovercover Blow clean thoroughly around the gearbox. Collect the oil spill when the side cover has been removed. Remove the nut for the clamp and the bracket holding the wiring. Cut off the tie straps (2) holding cable harness

Page 5 of 6"VCC-118836 EN 2010-10-24"


above the bracket. Push the wiring to one side to access the screw. Remove the screw and the bracket. Remove all the screws from the side cover (the lower 5 screws are Torx screws). Caution! Caution! Caution! Caution! Ensure that the lower and outer Ensure that the lower and outer Ensure that the lower and outer Ensure that the lower and outer screws align correctly during installation.screws align correctly during installation.screws align correctly during installation.screws align correctly during installation.

Removing the gearbox side coverRemoving the gearbox side coverRemoving the gearbox side coverRemoving the gearbox side cover

Pull out the side cover slightly from the gearbox. Angle out the cover at the front on the left side quite a lot. Pull the cover backwards to the steering gear. Pull out the cover at the bottom edge so that the upper section passes the side member.

Finishing workFinishing workFinishing workFinishing work

Note! Note! Note! Note! The gasket may only be reThe gasket may only be reThe gasket may only be reThe gasket may only be re----used used used used once.Check whether there is a 2 at the top of once.Check whether there is a 2 at the top of once.Check whether there is a 2 at the top of once.Check whether there is a 2 at the top of the rightthe rightthe rightthe right----hand corner of the gasket. The gasket hand corner of the gasket. The gasket hand corner of the gasket. The gasket hand corner of the gasket. The gasket must be replaced if there is a 2 on it.If there is must be replaced if there is a 2 on it.If there is must be replaced if there is a 2 on it.If there is must be replaced if there is a 2 on it.If there is no digit, stamp a 2. This indicates that the no digit, stamp a 2. This indicates that the no digit, stamp a 2. This indicates that the no digit, stamp a 2. This indicates that the gasket has now been reused and must be gasket has now been reused and must be gasket has now been reused and must be gasket has now been reused and must be replaced the next time the side cover is replaced the next time the side cover is replaced the next time the side cover is replaced the next time the side cover is removed. Make this mark to assist other removed. Make this mark to assist other removed. Make this mark to assist other removed. Make this mark to assist other mechanics.mechanics.mechanics.mechanics. ReplaceReplaceReplaceReplace the old rubber gasket which seals around the drive shaft.

Page 6 of 6"VCC-118836 EN 2010-10-24"


Note when disconnecting/connecting the battery leadNote when disconnecting/connecting the battery leadNote when disconnecting/connecting the battery leadNote when disconnecting/connecting the battery lead Note before disconnecting the battery leadNote before disconnecting the battery leadNote before disconnecting the battery leadNote before disconnecting the battery lead

Warning! Warning! Warning! Warning! The SRS (supplemental restraint The SRS (supplemental restraint The SRS (supplemental restraint The SRS (supplemental restraint system) is active for a certain time after the system) is active for a certain time after the system) is active for a certain time after the system) is active for a certain time after the power is cut. Therefore wait 3 minutes before power is cut. Therefore wait 3 minutes before power is cut. Therefore wait 3 minutes before power is cut. Therefore wait 3 minutes before starting work.starting work.starting work.starting work.

If the malfunction indicator lamp (MIL) lights, read off the diagnostic trouble codes (DTCs) for the engine management system. If necessary, remedy any faults before cutting the power to the car When the ignition has been switched off, wait at least 5 minutes before cutting the power to the car. This is so that there is sufficient time for information to be stored in the control modules If the vehicle has a heater with remote starting, the personal code is reset to the factory default (1234) if the battery is disconnected or the power is cut.

Caution! Caution! Caution! Caution! Always disconnect the battery Always disconnect the battery Always disconnect the battery Always disconnect the battery negative lead.negative lead.negative lead.negative lead. Do NOT disconnect the positive lead in the Do NOT disconnect the positive lead in the Do NOT disconnect the positive lead in the Do NOT disconnect the positive lead in the engine compartment.engine compartment.engine compartment.engine compartment.

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Note before connecting the battery leadNote before connecting the battery leadNote before connecting the battery leadNote before connecting the battery lead

Warning! Warning! Warning! Warning! The key must be in position 2. No The key must be in position 2. No The key must be in position 2. No The key must be in position 2. No one must be in the car when the battery is one must be in the car when the battery is one must be in the car when the battery is one must be in the car when the battery is connected. This is a safety precaution in case connected. This is a safety precaution in case connected. This is a safety precaution in case connected. This is a safety precaution in case an airbag module activates when the power is an airbag module activates when the power is an airbag module activates when the power is an airbag module activates when the power is connected.connected.connected.connected.

Note after connecting the battery leadNote after connecting the battery leadNote after connecting the battery leadNote after connecting the battery lead Initializing the upper electronic module (UEM)Initializing the upper electronic module (UEM)Initializing the upper electronic module (UEM)Initializing the upper electronic module (UEM) Applies only to S80 after chassis number 29668 Applies only to S80 after chassis number 29668 Applies only to S80 after chassis number 29668 Applies only to S80 after chassis number 29668 and all S60/V70/XC70/XC90.and all S60/V70/XC70/XC90.and all S60/V70/XC70/XC90.and all S60/V70/XC70/XC90. Initialize the central locking, interior lighting and sun roof by unlocking the car using a remote control, key or VIDA vehicle communication. Calibrating the blower fan

If the car is equipped with Manual (MCC) or Standard climate control, the blower fan speed must recalibrated if the battery has been disconnected Ignition on

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Page 1 of 2"VCC-104452 EN 2010-10-24"


Turn the blower fan switch to maximum Turn the blower fan switch to minimum The calibration is complete.

Calibrating the sun roof For S80, S60, V70 (00-) and V70 XC (01-) / XC70 see: Sun roof module (SRM), Sun roof module (SRM), Sun roof module (SRM), Sun roof module (SRM), calibratingcalibratingcalibratingcalibrating For XC90, see: Sun roof module (SRM), Sun roof module (SRM), Sun roof module (SRM), Sun roof module (SRM), calibratingcalibratingcalibratingcalibrating ..

Engine When the battery has been disconnected, the car may have to be driven for a few minutes before the engine runs normally.

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Page 2 of 2"VCC-104452 EN 2010-10-24"


Remove the air cleaner (ACL) housingRemove the air cleaner (ACL) housingRemove the air cleaner (ACL) housingRemove the air cleaner (ACL) housing

Pull the air intake backwards (towards the engine) so that it disconnects from its mounting under the front cover plate. Disconnect the hose clamp for the air hose. Remove all the air hoses and connectors from the air cleaner (ACL). Remove the air cleaner (ACL) housing from its mountings. Pull it straight up.

Page 1 of 1"VCC-091234 EN 2010-10-24"


Removing the charge air hose and the hose Removing the charge air hose and the hose Removing the charge air hose and the hose Removing the charge air hose and the hose clamp (turbocharged cars)clamp (turbocharged cars)clamp (turbocharged cars)clamp (turbocharged cars)

Undo the hose clamp at the twin pipe. Remove the hose from the twin pipe.

Page 1 of 1"VCC-095998 EN 2010-10-24"


Installing the lifting beam and lifting hook on Installing the lifting beam and lifting hook on Installing the lifting beam and lifting hook on Installing the lifting beam and lifting hook on the engine lifting eyelet the engine lifting eyelet the engine lifting eyelet the engine lifting eyelet

Note! Note! Note! Note! Position the stand for lifting beam Position the stand for lifting beam Position the stand for lifting beam Position the stand for lifting beam 999 999 999 999 5716571657165716 on the upper wheel arch members. on the upper wheel arch members. on the upper wheel arch members. on the upper wheel arch members. Then position the lifting beam directly above the engine lifting eyes on both sides. Connect lifting hook 999 5460999 5460999 5460999 5460 . Tighten to light contact.

Page 1 of 1"VCC-095998 EN 2010-10-24"


Disconnecting the front suspension Disconnecting the front suspension Disconnecting the front suspension Disconnecting the front suspension componentscomponentscomponentscomponents

Raise the carRaise the carRaise the carRaise the car Note! Note! Note! Note! Position the front lift arms so that they do Position the front lift arms so that they do Position the front lift arms so that they do Position the front lift arms so that they do not obstruct the subnot obstruct the subnot obstruct the subnot obstruct the sub----frame support plates.frame support plates.frame support plates.frame support plates. Remove:

the front wheels the splash guard under the engine both the screws for the front splash guard. Remove the cover: Press in the catches at the front edge of the cover. Pull the cover backwards.

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Page 1 of 1"VCC-095998 EN 2010-10-24"


Remove the ball joint nut (both sides)Remove the ball joint nut (both sides)Remove the ball joint nut (both sides)Remove the ball joint nut (both sides)

Remove the nut for the lower ball joint and control arm. Clean the exposed threads outside the nut. Spray using rust solvent before removing the nut. Counterhold with Torx TX 40 at the ball joint pinion when removing the nut. This is so that the ball joint boot does not turn.

Page 1 of 1"VCC-092045 EN 2010-10-24"


Remove the control arms for the antiRemove the control arms for the antiRemove the control arms for the antiRemove the control arms for the anti----roll bar, roll bar, roll bar, roll bar, the track rod and the screw from the drive shaft the track rod and the screw from the drive shaft the track rod and the screw from the drive shaft the track rod and the screw from the drive shaft on both sideson both sideson both sideson both sides

Remove: the link for the anti-roll bar up at the spring strut. Counterhold using Torx 30. The rubber boot must not be twisted the track rod from the stub axle. Use puller 999 5259999 5259999 5259999 5259 the screw for the drive shaft.

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Page 1 of 1"VCC-092045 EN 2010-10-24"


Remove the screws from Remove the screws from Remove the screws from Remove the screws from the subthe subthe subthe sub----frame frame frame frame support plates (both sides)support plates (both sides)support plates (both sides)support plates (both sides)

Preparations for removal of the stub axle position fixture 998 5972998 5972998 5972998 5972 (light contact) under the right-hand side of the sub-frame slacken off both the sub-frame screws completely. Screw the screws back in approximately 5 turns lower the sub-frame so that it rests on the screws and the mobile jack.

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Page 1 of 1"VCC-092045 EN 2010-10-24"


Remove the stub axle from the control armRemove the stub axle from the control armRemove the stub axle from the control armRemove the stub axle from the control arm

Pry the control arm with a crowbar. At the same time, lift the stub axle off the control arm. Note! Note! Note! Note! Install socket Install socket Install socket Install socket 999 5562999 5562999 5562999 5562 on the stub axle on the stub axle on the stub axle on the stub axle ball joint. Do not damage the rubber bellow for ball joint. Do not damage the rubber bellow for ball joint. Do not damage the rubber bellow for ball joint. Do not damage the rubber bellow for the ball joint.the ball joint.the ball joint.the ball joint.

Page 1 of 1"VCC-092045 EN 2010-10-24"


Press up the subPress up the subPress up the subPress up the sub----frame on the rightframe on the rightframe on the rightframe on the right----hand sidehand sidehand sidehand side

Tighten the sub-frame screws to light contact. Then slacken off the screws approximately 4–5 turns. Note! Note! Note! Note! This is because the subThis is because the subThis is because the subThis is because the sub----frame hangs frame hangs frame hangs frame hangs down more on one side.down more on one side.down more on one side.down more on one side. Move the mobile jack to the left hand side.

Page 1 of 1"VCC-092045 EN 2010-10-24"


Removing gearbox side coverRemoving gearbox side coverRemoving gearbox side coverRemoving gearbox side cover Special tools: 998 5972998 5972998 5972998 5972 , 999 5460999 5460999 5460999 5460 , 999 5716999 5716999 5716999 5716 , 999 5736999 5736999 5736999 5736 , 999 5972999 5972999 5972999 5972

Note! Note! Note! Note! As the illustrations in this service As the illustrations in this service As the illustrations in this service As the illustrations in this service information are used for different model years information are used for different model years information are used for different model years information are used for different model years and / or models, some variation may occur. and / or models, some variation may occur. and / or models, some variation may occur. and / or models, some variation may occur. However, the essential information is always However, the essential information is always However, the essential information is always However, the essential information is always correct.correct.correct.correct. Disconnecting the battery leadDisconnecting the battery leadDisconnecting the battery leadDisconnecting the battery lead See Note when disconnecting/connecting the Note when disconnecting/connecting the Note when disconnecting/connecting the Note when disconnecting/connecting the battery leadbattery leadbattery leadbattery lead . It is essential that the instructions are followed. Removing engine compartment componentsRemoving engine compartment componentsRemoving engine compartment componentsRemoving engine compartment components

Removing the air cleaner (ACL) housingRemoving the air cleaner (ACL) housingRemoving the air cleaner (ACL) housingRemoving the air cleaner (ACL) housing Brake pipe master cylinder / ABS unit, Brake pipe master cylinder / ABS unit, Brake pipe master cylinder / ABS unit, Brake pipe master cylinder / ABS unit, replacingreplacingreplacingreplacing . Applies only to turbocharged carsApplies only to turbocharged carsApplies only to turbocharged carsApplies only to turbocharged cars Carefully heat around the pipe at the charge air cooler (CAC). Use a hot air gun. Loosen and remove the pipe.

Removing the upper torque rodRemoving the upper torque rodRemoving the upper torque rodRemoving the upper torque rod

Remove: the plastic covers over the spring strut mountings (applies only to early versions) the screws the screw and nut for the engine mounting.

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Collecting gearbox fluidCollecting gearbox fluidCollecting gearbox fluidCollecting gearbox fluid

Use an oil suction unit. Remove the dip stick. Extract all the fluid (6 litres). This is done to avoid oil spillage when the cover is removed.

Removing the charge air pipe and hoseRemoving the charge air pipe and hoseRemoving the charge air pipe and hoseRemoving the charge air pipe and hose

Page 1 of 6Gearbox, automatic


Remove the charge air pipe and the cooler hoses according to Gearbox, removingGearbox, removingGearbox, removingGearbox, removing . Removing the spark plugs coverRemoving the spark plugs coverRemoving the spark plugs coverRemoving the spark plugs cover Remove the spark plug cover according to Gearbox, removingGearbox, removingGearbox, removingGearbox, removing . Installing lifting fixtureInstalling lifting fixtureInstalling lifting fixtureInstalling lifting fixture

Remove the 2 screws at the engine mounting. Install lifting lug 999 5717999 5717999 5717999 5717 . Disconnect the ground strip.

Removing the connector from the gearboxRemoving the connector from the gearboxRemoving the connector from the gearboxRemoving the connector from the gearbox

Remove: the screw for the clamp holding the positive cable on the engine the connector from the gearbox (press the connector together). Pull it from the gearbox.

Remove the cable from its clips on the side member.

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Installing the lifting beam and lifting hook on Installing the lifting beam and lifting hook on Installing the lifting beam and lifting hook on Installing the lifting beam and lifting hook on the engine lifting eyelet the engine lifting eyelet the engine lifting eyelet the engine lifting eyelet Install the lifting beam and the lifting hook on the engine lifting lugs. See Gearbox, Gearbox, Gearbox, Gearbox, removingremovingremovingremoving . Disconnecting the front suspension Disconnecting the front suspension Disconnecting the front suspension Disconnecting the front suspension componentscomponentscomponentscomponents Remove the front end components according to Gearbox, removingGearbox, removingGearbox, removingGearbox, removing . Removing the screws from the cable conduit Removing the screws from the cable conduit Removing the screws from the cable conduit Removing the screws from the cable conduit and the parking heater. Removing the ground and the parking heater. Removing the ground and the parking heater. Removing the ground and the parking heater. Removing the ground lead bracket from the sublead bracket from the sublead bracket from the sublead bracket from the sub----frameframeframeframe Remove:

the screw for the front engine pad (see the arrow) the screws for the torque rod in the gearbox.

Applies only to cars with parking heaters:Applies only to cars with parking heaters:Applies only to cars with parking heaters:Applies only to cars with parking heaters:

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Remove the fuel line from its clips on the sub-frame. Hang up the parking heater in a tie strap.

Removing the ball joint nut (left hand side)Removing the ball joint nut (left hand side)Removing the ball joint nut (left hand side)Removing the ball joint nut (left hand side) Remove the ball joint nut (left hand side) according to Gearbox, removingGearbox, removingGearbox, removingGearbox, removing . Removing the control arms for the antiRemoving the control arms for the antiRemoving the control arms for the antiRemoving the control arms for the anti----roll bar, roll bar, roll bar, roll bar, the track rod and the screw from the drive shaft the track rod and the screw from the drive shaft the track rod and the screw from the drive shaft the track rod and the screw from the drive shaft on the left hand sideon the left hand sideon the left hand sideon the left hand side Only slacken off the brake pipe bracket on the left-hand side. Remove the control arms for the anti-roll bar, the track rod and the screw from the drive shaft on both sides according to Gearbox, Gearbox, Gearbox, Gearbox, removingremovingremovingremoving . Removing the screws from the subRemoving the screws from the subRemoving the screws from the subRemoving the screws from the sub----frame frame frame frame support plates (both sides)support plates (both sides)support plates (both sides)support plates (both sides) Remove the screws from the sub-frame support plates (both sides) according to Gearbox, removingGearbox, removingGearbox, removingGearbox, removing . Removing the pipe lines from the subRemoving the pipe lines from the subRemoving the pipe lines from the subRemoving the pipe lines from the sub----frameframeframeframe

Unhook the servo pipe and the evaporator pipe from the holders on the right-hand side of the sub-frame. Unhook the servo pipe from the clip on the sub-frame.

Removing the stub axle from the control armRemoving the stub axle from the control armRemoving the stub axle from the control armRemoving the stub axle from the control arm Remove the stub axle from the control arm according to Gearbox, removingGearbox, removingGearbox, removingGearbox, removing . Pressing up the subPressing up the subPressing up the subPressing up the sub----frame on the rightframe on the rightframe on the rightframe on the right----hand hand hand hand sidesidesideside Press up the sub-frame on the right-hand side according to Gearbox, removingGearbox, removingGearbox, removingGearbox, removing .



Removing the front cross memberRemoving the front cross memberRemoving the front cross memberRemoving the front cross member Remove the front cross member according to Gearbox, removingGearbox, removingGearbox, removingGearbox, removing . Removing the bracket for the heated oxygen Removing the bracket for the heated oxygen Removing the bracket for the heated oxygen Removing the bracket for the heated oxygen sensor (HO2S) wiringsensor (HO2S) wiringsensor (HO2S) wiringsensor (HO2S) wiring

Remove the screws for the bracket in the sub-frame holding the heated oxygen sensor (HO2S) cable. Push the bracket to one side.

Preparatory work for removing the stub axle on Preparatory work for removing the stub axle on Preparatory work for removing the stub axle on Preparatory work for removing the stub axle on the leftthe leftthe leftthe left----hand sidehand sidehand sidehand side Preparations, see Gearbox, removingGearbox, removingGearbox, removingGearbox, removing . Removing the drive shaft from the stub axle Removing the drive shaft from the stub axle Removing the drive shaft from the stub axle Removing the drive shaft from the stub axle (left(left(left(left----hand side) hand side) hand side) hand side) Remove the drive shaft from the stub axle. See Gearbox, removingGearbox, removingGearbox, removingGearbox, removing . Removing the left drive shaft from the gearboxRemoving the left drive shaft from the gearboxRemoving the left drive shaft from the gearboxRemoving the left drive shaft from the gearbox

Use 2 gimmy bars999 5736999 5736999 5736999 5736 . Note! Note! Note! Note! Do not damage the seal.Do not damage the seal.Do not damage the seal.Do not damage the seal. Note! Note! Note! Note! Do not under any circumstancesDo not under any circumstancesDo not under any circumstancesDo not under any circumstances pull the pull the pull the pull the drive shaft in such a way that could cause the drive shaft in such a way that could cause the drive shaft in such a way that could cause the drive shaft in such a way that could cause the joints to separate. The joints do not have axial joints to separate. The joints do not have axial joints to separate. The joints do not have axial joints to separate. The joints do not have axial pinions.pinions.pinions.pinions.

Removing the nuts and screws for the steering Removing the nuts and screws for the steering Removing the nuts and screws for the steering Removing the nuts and screws for the steering gear subgear subgear subgear sub----frame frame frame frame Remove the nuts and screws according to Gearbox, removingGearbox, removingGearbox, removingGearbox, removing . Removing the collision protection system over Removing the collision protection system over Removing the collision protection system over Removing the collision protection system over the steering gearthe steering gearthe steering gearthe steering gear Applies only to rightApplies only to rightApplies only to rightApplies only to right----hand drive carshand drive carshand drive carshand drive cars Remove the collision protection system according to Gearbox, removingGearbox, removingGearbox, removingGearbox, removing . Lowering the subLowering the subLowering the subLowering the sub----frameframeframeframe



Use the mobile jack. Lower the sub-frame approximately 5 cm. Hang up the steering gear in a tie strap. Carefully lower the sub-frame. Let it hang free. Note! Note! Note! Note! Ensure that the screws for the steering Ensure that the screws for the steering Ensure that the screws for the steering Ensure that the screws for the steering gear release from the frame.gear release from the frame.gear release from the frame.gear release from the frame.

Removing the screw for the rear engine Removing the screw for the rear engine Removing the screw for the rear engine Removing the screw for the rear engine mountingmountingmountingmounting Remove the screw for the rear engine pad according to Gearbox, removingGearbox, removingGearbox, removingGearbox, removing . Removing the rear engine mountingRemoving the rear engine mountingRemoving the rear engine mountingRemoving the rear engine mounting Remove the rear engine mounting according to Gearbox, removingGearbox, removingGearbox, removingGearbox, removing . Preparations for removal of the gearbox side Preparations for removal of the gearbox side Preparations for removal of the gearbox side Preparations for removal of the gearbox side plateplateplateplate

Preparatory work can be carried out when the vehicle is lowered. Remove the 2 nuts from the wing liner. Angle out and tie up the wing liner to the lifting beam. Use a retaining strap. Note! Note! Note! Note! Do not damage the front wing.Do not damage the front wing.Do not damage the front wing.Do not damage the front wing.

Removing the oil pipes from the gearboxRemoving the oil pipes from the gearboxRemoving the oil pipes from the gearboxRemoving the oil pipes from the gearbox Remove the oil pipes according to Gearbox, Gearbox, Gearbox, Gearbox, removingremovingremovingremoving . Lowering the engine and gearboxLowering the engine and gearboxLowering the engine and gearboxLowering the engine and gearbox Caution! Caution! Caution! Caution! Do not damage the exhaust boots.Do not damage the exhaust boots.Do not damage the exhaust boots.Do not damage the exhaust boots. Lower the engine and gearbox according to Gearbox, removingGearbox, removingGearbox, removingGearbox, removing . Preparations for removal of the gearbox side Preparations for removal of the gearbox side Preparations for removal of the gearbox side Preparations for removal of the gearbox side covercovercovercover Blow clean thoroughly around the gearbox. Collect the oil spill when the side cover has been removed. Remove the nut for the clamp and the bracket holding the wiring. Cut off the tie straps (2) holding cable harness



above the bracket. Push the wiring to one side to access the screw. Remove the screw and the bracket. Remove all the screws from the side cover (the lower 5 screws are Torx screws). Caution! Caution! Caution! Caution! Ensure that the lower and outer Ensure that the lower and outer Ensure that the lower and outer Ensure that the lower and outer screws align correctly during installation.screws align correctly during installation.screws align correctly during installation.screws align correctly during installation.

Removing the gearbox side coverRemoving the gearbox side coverRemoving the gearbox side coverRemoving the gearbox side cover

Pull out the side cover slightly from the gearbox. Angle out the cover at the front on the left side quite a lot. Pull the cover backwards to the steering gear. Pull out the cover at the bottom edge so that the upper section passes the side member.

Finishing workFinishing workFinishing workFinishing work

Note! Note! Note! Note! The gasket may only be reThe gasket may only be reThe gasket may only be reThe gasket may only be re----used used used used once.Check whether there is a 2 at the top of once.Check whether there is a 2 at the top of once.Check whether there is a 2 at the top of once.Check whether there is a 2 at the top of the rightthe rightthe rightthe right----hand corner of the gasket. The gasket hand corner of the gasket. The gasket hand corner of the gasket. The gasket hand corner of the gasket. The gasket must be replaced if there is a 2 on it.If there is must be replaced if there is a 2 on it.If there is must be replaced if there is a 2 on it.If there is must be replaced if there is a 2 on it.If there is no digit, stamp a 2. This indicates that the no digit, stamp a 2. This indicates that the no digit, stamp a 2. This indicates that the no digit, stamp a 2. This indicates that the gasket has now been reused and must be gasket has now been reused and must be gasket has now been reused and must be gasket has now been reused and must be replaced the next time the side cover is replaced the next time the side cover is replaced the next time the side cover is replaced the next time the side cover is removed. Make this mark to assist other removed. Make this mark to assist other removed. Make this mark to assist other removed. Make this mark to assist other mechanics.mechanics.mechanics.mechanics. ReplaceReplaceReplaceReplace the old rubber gasket which seals around the drive shaft.



Preparatory work for removing the stub axle on Preparatory work for removing the stub axle on Preparatory work for removing the stub axle on Preparatory work for removing the stub axle on the leftthe leftthe leftthe left----hand sidehand sidehand sidehand side

Position fixture 998 5972998 5972998 5972998 5972 under the sub-frame. Remove the sub-frame screws. Lower the sub-frame so that the ball joint for the stub axle detaches. Note! Note! Note! Note! Install socket Install socket Install socket Install socket 999 5562999 5562999 5562999 5562 on the stub axle on the stub axle on the stub axle on the stub axle ball joint. Do not damage the rubber bellow for ball joint. Do not damage the rubber bellow for ball joint. Do not damage the rubber bellow for ball joint. Do not damage the rubber bellow for the ball joint.the ball joint.the ball joint.the ball joint.

Page 1 of 1"VCC-095998 EN 2010-10-24"


Removing the nuts and screws for the steering Removing the nuts and screws for the steering Removing the nuts and screws for the steering Removing the nuts and screws for the steering gear subgear subgear subgear sub----frame frame frame frame

Remove the nuts and the screws from the steering gear sub-frame.

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Removing the screw for the rear engine Removing the screw for the rear engine Removing the screw for the rear engine Removing the screw for the rear engine mountingmountingmountingmounting

Remove the screw.

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Removing the rear engine mountingRemoving the rear engine mountingRemoving the rear engine mountingRemoving the rear engine mounting

Slacken off the 4 screws for the engine mounting. Twist out and remove the engine mounting.

Page 1 of 1"VCC-095998 EN 2010-10-24"


Removing the oil pipe from the gearboxRemoving the oil pipe from the gearboxRemoving the oil pipe from the gearboxRemoving the oil pipe from the gearbox

Note! Note! Note! Note! Plug the oil pipes so that no dirt gets in.Plug the oil pipes so that no dirt gets in.Plug the oil pipes so that no dirt gets in.Plug the oil pipes so that no dirt gets in. Remove the nuts from the brackets for the oil pipes. Remove the screw nipples (counterhold at the connections). Pull out the oil pipes. Move the oil pipes to one side. Lower the car.

Page 1 of 1"VCC-095998 EN 2010-10-24"


Lowering the engine and gearboxLowering the engine and gearboxLowering the engine and gearboxLowering the engine and gearbox

Lower the engine / gearbox on the left-hand side using the hook. Lower the engine so that the distance between the upper edge of the mounting bracket and the spark plug cover is approximately 350 mm350 mm350 mm350 mm. See arrow. Caution! Caution! Caution! Caution! Ensure that the engine mounting is Ensure that the engine mounting is Ensure that the engine mounting is Ensure that the engine mounting is not against the exhaust boot and is not not against the exhaust boot and is not not against the exhaust boot and is not not against the exhaust boot and is not trapped. The exhaust boot must not be trapped. The exhaust boot must not be trapped. The exhaust boot must not be trapped. The exhaust boot must not be damaged.damaged.damaged.damaged. Raise the carRaise the carRaise the carRaise the car

Page 1 of 1"VCC-095998 EN 2010-10-24"


Installing the gearbox side coverInstalling the gearbox side coverInstalling the gearbox side coverInstalling the gearbox side cover Note! Note! Note! Note! As the illustrations in this service As the illustrations in this service As the illustrations in this service As the illustrations in this service information are used for different model years information are used for different model years information are used for different model years information are used for different model years and / or models, some variation may occur. and / or models, some variation may occur. and / or models, some variation may occur. and / or models, some variation may occur. However, the essential information is always However, the essential information is always However, the essential information is always However, the essential information is always correct.correct.correct.correct. Note! Note! Note! Note! Carefully clean the gearbox and side Carefully clean the gearbox and side Carefully clean the gearbox and side Carefully clean the gearbox and side cover mating surfaces before installing the cover mating surfaces before installing the cover mating surfaces before installing the cover mating surfaces before installing the gasket. Paper must not be used for cleaning. gasket. Paper must not be used for cleaning. gasket. Paper must not be used for cleaning. gasket. Paper must not be used for cleaning. Paper fragments can cause running problems. Paper fragments can cause running problems. Paper fragments can cause running problems. Paper fragments can cause running problems. Check the marking on the side cover gasket. Check the marking on the side cover gasket. Check the marking on the side cover gasket. Check the marking on the side cover gasket. The gasket can be reused once.The gasket can be reused once.The gasket can be reused once.The gasket can be reused once. PreparationsPreparationsPreparationsPreparations

Note! Note! Note! Note! The gasket may only be reThe gasket may only be reThe gasket may only be reThe gasket may only be re----used used used used once.Check whether there is a 2 at the top of once.Check whether there is a 2 at the top of once.Check whether there is a 2 at the top of once.Check whether there is a 2 at the top of the rightthe rightthe rightthe right----hand corner of the gasket. The gasket hand corner of the gasket. The gasket hand corner of the gasket. The gasket hand corner of the gasket. The gasket must be replaced if there is a 2 on it.If there is must be replaced if there is a 2 on it.If there is must be replaced if there is a 2 on it.If there is must be replaced if there is a 2 on it.If there is no digit, stamp a 2. This indicates that the no digit, stamp a 2. This indicates that the no digit, stamp a 2. This indicates that the no digit, stamp a 2. This indicates that the gasket has now been reused and must be gasket has now been reused and must be gasket has now been reused and must be gasket has now been reused and must be replaced the next time the side cover is replaced the next time the side cover is replaced the next time the side cover is replaced the next time the side cover is removed. Make this mark to assist other removed. Make this mark to assist other removed. Make this mark to assist other removed. Make this mark to assist other mechanics.mechanics.mechanics.mechanics. Note! Note! Note! Note! Apply a little petroleum jelly to the new Apply a little petroleum jelly to the new Apply a little petroleum jelly to the new Apply a little petroleum jelly to the new rubber gasketrubber gasketrubber gasketrubber gasket which seals around the drive which seals around the drive which seals around the drive which seals around the drive shaft outlet. This is so that it stays in place in shaft outlet. This is so that it stays in place in shaft outlet. This is so that it stays in place in shaft outlet. This is so that it stays in place in the groove in the side cover on installation.the groove in the side cover on installation.the groove in the side cover on installation.the groove in the side cover on installation. Installing coverInstalling coverInstalling coverInstalling cover

Note! Note! Note! Note! The side cover has two different holes. The side cover has two different holes. The side cover has two different holes. The side cover has two different holes. The rear smaller hole and the front rectangular The rear smaller hole and the front rectangular The rear smaller hole and the front rectangular The rear smaller hole and the front rectangular hole. These two holes are to guide the cover hole. These two holes are to guide the cover hole. These two holes are to guide the cover hole. These two holes are to guide the cover gasket during installation. Begin installing the gasket during installation. Begin installing the gasket during installation. Begin installing the gasket during installation. Begin installing the cover by installing the two screws.cover by installing the two screws.cover by installing the two screws.cover by installing the two screws. Apply a little petroleum jelly to the gearbox mating surface. Install:

the side cover gasket the side cover the screws. First tighten the screws crosswise to 10 Nm10 Nm10 Nm10 Nm. Then tighten the screws crosswise to 25 Nm25 Nm25 Nm25 Nm the lower three Torx screws. Tighten to 25 Nm25 Nm25 Nm25 Nm the bracket for the studs and the screw loosely on the bracket the clamp for the stud and the screw. Tighten to 25 Nm25 Nm25 Nm25 Nm. Tighten the screw for the

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Page 1 of 7"VCC-118956 EN 2010-10-24"


bracket. Tighten to 25 Nm25 Nm25 Nm25 Nm. Clamp the wiring up on the bracket. Use new tie straps. Lifting the engine and gearbox to the horizontal Lifting the engine and gearbox to the horizontal Lifting the engine and gearbox to the horizontal Lifting the engine and gearbox to the horizontal positionpositionpositionposition

Installing the oil pipesInstalling the oil pipesInstalling the oil pipesInstalling the oil pipes

Install: the oil pipe with the nipple to the terminal on the gearbox. Counterhold on the connection. Tighten to 30 Nm30 Nm30 Nm30 Nm the nut and washer for the oil pipe brackets. Tighten to 25 Nm25 Nm25 Nm25 Nm.

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Installing the rear engine mountingInstalling the rear engine mountingInstalling the rear engine mountingInstalling the rear engine mounting Install the rear engine mounting according to Transmission, installingTransmission, installingTransmission, installingTransmission, installing . Installing the screw for the rear engine pad Installing the screw for the rear engine pad Installing the screw for the rear engine pad Installing the screw for the rear engine pad through the steering gear through the steering gear through the steering gear through the steering gear Install the screw for the rear engine pad according to Transmission, installingTransmission, installingTransmission, installingTransmission, installing . Installing the collision protection system over Installing the collision protection system over Installing the collision protection system over Installing the collision protection system over the steering gearthe steering gearthe steering gearthe steering gear Applies only to rightApplies only to rightApplies only to rightApplies only to right----hand drive carshand drive carshand drive carshand drive cars Install the collision protection on the steering gear according to Transmission, installingTransmission, installingTransmission, installingTransmission, installing . Installing the subInstalling the subInstalling the subInstalling the sub----frame on the bodyworkframe on the bodyworkframe on the bodyworkframe on the bodywork Install the sub-frame on the bodywork according to Transmission, installingTransmission, installingTransmission, installingTransmission, installing . Installing the left drive shaft on the gearbox, Installing the left drive shaft on the gearbox, Installing the left drive shaft on the gearbox, Installing the left drive shaft on the gearbox, stub axle and control armstub axle and control armstub axle and control armstub axle and control arm Install the left drive shaft in the gearbox

Page 2 of 7"VCC-118956 EN 2010-10-24"


according to Transmission, installingTransmission, installingTransmission, installingTransmission, installing . Installing and tightening the subInstalling and tightening the subInstalling and tightening the subInstalling and tightening the sub----frame screwsframe screwsframe screwsframe screws Install and tighten the sub-frame screws according to Transmission, installingTransmission, installingTransmission, installingTransmission, installing . Installing the screws for the bracket for the Installing the screws for the bracket for the Installing the screws for the bracket for the Installing the screws for the bracket for the heated oxygen sensor (HO2S) cableheated oxygen sensor (HO2S) cableheated oxygen sensor (HO2S) cableheated oxygen sensor (HO2S) cable Install the screws for the bracket for the heated oxygen sensor (HO2S) cable according to Transmission, installingTransmission, installingTransmission, installingTransmission, installing . Installing the front cross memberInstalling the front cross memberInstalling the front cross memberInstalling the front cross member

Install: the screws for the exhaust pipe mounting. Tighten to 10 Nm10 Nm10 Nm10 Nm the brake pipe in its holders the screws for the cross member. Tighten to 25 Nm25 Nm25 Nm25 Nm.

Secure the heat deflector using rivets (early version).

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Installing new lock nuts on the steering gearInstalling new lock nuts on the steering gearInstalling new lock nuts on the steering gearInstalling new lock nuts on the steering gear Install new lock nuts on the steering gear according to Transmission, installingTransmission, installingTransmission, installingTransmission, installing . Installing the screw for the front engine pad Installing the screw for the front engine pad Installing the screw for the front engine pad Installing the screw for the front engine pad and the torque rod mounting in the gearboxand the torque rod mounting in the gearboxand the torque rod mounting in the gearboxand the torque rod mounting in the gearbox Install the screw for the front engine pad and the torque rod mounting in the gearbox. See Transmission, installingTransmission, installingTransmission, installingTransmission, installing . Installing the screws for the cable conduit and Installing the screws for the cable conduit and Installing the screws for the cable conduit and Installing the screws for the cable conduit and the ground lead bracket the ground lead bracket the ground lead bracket the ground lead bracket

Tighten to 10 Nm10 Nm10 Nm10 Nm. Note! Note! Note! Note! Cars with parking heaters: Install the Cars with parking heaters: Install the Cars with parking heaters: Install the Cars with parking heaters: Install the heater in the bracket. Tighten the nuts. Tighten heater in the bracket. Tighten the nuts. Tighten heater in the bracket. Tighten the nuts. Tighten heater in the bracket. Tighten the nuts. Tighten to 25 Nm.to 25 Nm.to 25 Nm.to 25 Nm. Reinstall the fuel line in the clips on the sub-frame.

Installing and tightening front end components Installing and tightening front end components Installing and tightening front end components Installing and tightening front end components (both sides)(both sides)(both sides)(both sides) Install and tighten the front end components according to Transmission, installingTransmission, installingTransmission, installingTransmission, installing .

Page 3 of 7"VCC-118956 EN 2010-10-24"


Tightening the ball joint pinionTightening the ball joint pinionTightening the ball joint pinionTightening the ball joint pinion Tighten the ball joint pinion according to Transmission, installingTransmission, installingTransmission, installingTransmission, installing . Lower the car. Remove the lifting beam and the lifting hook Remove the lifting beam and the lifting hook Remove the lifting beam and the lifting hook Remove the lifting beam and the lifting hook from the engine and the car from the engine and the car from the engine and the car from the engine and the car

Remove the lifting fixture from the motor. Reinstall the screws. Tighten to 50 Nm50 Nm50 Nm50 Nm. Reinstall the spark plug cover. Tighten the screws. Tighten to 10 Nm. Install the ground strip. Tighten to 10 Nm10 Nm10 Nm10 Nm. Applies only to turbocharged carsApplies only to turbocharged carsApplies only to turbocharged carsApplies only to turbocharged cars Lift up the delivery lines. Install the spark plug cover. Tighten the screws. Installing all the charge air pipesInstalling all the charge air pipesInstalling all the charge air pipesInstalling all the charge air pipes

Applies only to turbocharged carsApplies only to turbocharged carsApplies only to turbocharged carsApplies only to turbocharged cars Connect all the charge air pipes to each other. Tighten the hose clamps. Install the screws for the charge air pipe in the intake manifold. Tighten to 10 Nm10 Nm10 Nm10 Nm.

Install the hose on the heater pipe in the bulkhead. Press the radiator hose quick-release connector into place on the heater pipe. Check:Check:Check:Check: Pull the hose.

Installing the connectorInstalling the connectorInstalling the connectorInstalling the connector

Install: the screw for the clamp for the positive cable the cable in the clips on the side member the connector for the gearbox. Press it into place properly. Caution! Caution! Caution! Caution! It is important that the connector is It is important that the connector is It is important that the connector is It is important that the connector is pushed into place properly. If it is not pushed into place properly. If it is not pushed into place properly. If it is not pushed into place properly. If it is not correctly connected the gear shift function correctly connected the gear shift function correctly connected the gear shift function correctly connected the gear shift function

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Page 4 of 7"VCC-118956 EN 2010-10-24"


may stop.may stop.may stop.may stop. Installing the upper torque rodInstalling the upper torque rodInstalling the upper torque rodInstalling the upper torque rod

Install: the torque rod. Tighten the mounting screws. Tighten to 50 Nm50 Nm50 Nm50 Nm the screw and a new nut for the engine mounting. Tighten to 80 Nm80 Nm80 Nm80 Nm the plastic guard over the spring strut (if applicable). Tighten the screws.

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Installing the air cleaner (ACL) housingInstalling the air cleaner (ACL) housingInstalling the air cleaner (ACL) housingInstalling the air cleaner (ACL) housing Install the air cleaner (ACL) housing according to Brake pipe master cylinder / ABS unit, Brake pipe master cylinder / ABS unit, Brake pipe master cylinder / ABS unit, Brake pipe master cylinder / ABS unit, replacingreplacingreplacingreplacing . Filling the gearbox with fluidFilling the gearbox with fluidFilling the gearbox with fluidFilling the gearbox with fluid Note! Note! Note! Note! Oil grade: Only automatic gearbox fluid Oil grade: Only automatic gearbox fluid Oil grade: Only automatic gearbox fluid Oil grade: Only automatic gearbox fluid (ATF).(ATF).(ATF).(ATF). Dexron III (the fluid must have a G license)*.Dexron III (the fluid must have a G license)*.Dexron III (the fluid must have a G license)*.Dexron III (the fluid must have a G license)*. *This is usually given as *This is usually given as *This is usually given as *This is usually given as ““““Dexron III (GDexron III (GDexron III (GDexron III (G----xxxxx)xxxxx)xxxxx)xxxxx)” ” ” ” where xxxxx is a 5 digit serial number. where xxxxx is a 5 digit serial number. where xxxxx is a 5 digit serial number. where xxxxx is a 5 digit serial number. ““““Dexron Dexron Dexron Dexron IIIIIIIIIIII----GGGG” ” ” ” ((((without a number) may also occur.without a number) may also occur.without a number) may also occur.without a number) may also occur. Dexron II D and II E must Dexron II D and II E must Dexron II D and II E must Dexron II D and II E must notnotnotnot be used. be used. be used. be used. Note! Note! Note! Note! Filling with oil: Start by filling with Filling with oil: Start by filling with Filling with oil: Start by filling with Filling with oil: Start by filling with 5.5 litres of oil.5.5 litres of oil.5.5 litres of oil.5.5 litres of oil. Refilling gearbox oil There are three different Refilling gearbox oil There are three different Refilling gearbox oil There are three different Refilling gearbox oil There are three different methods. Method 1methods. Method 1methods. Method 1methods. Method 1

Note! Note! Note! Note! Filling with oil: Start by filling with Filling with oil: Start by filling with Filling with oil: Start by filling with Filling with oil: Start by filling with 5.5 litres of oil.5.5 litres of oil.5.5 litres of oil.5.5 litres of oil. Fill the gearbox with oil. Use a funnel with a plastic hose. Fill through the dipstick pipe. Clear up any oil spillage under the dip stick pipe.

Refilling gearbox oil Methods 2 and 3Refilling gearbox oil Methods 2 and 3Refilling gearbox oil Methods 2 and 3Refilling gearbox oil Methods 2 and 3 Note! Note! Note! Note! Filling with oil: Start by filling with Filling with oil: Start by filling with Filling with oil: Start by filling with Filling with oil: Start by filling with 5.5 litres of oil.5.5 litres of oil.5.5 litres of oil.5.5 litres of oil. Method 2Method 2Method 2Method 2 Use a converted five litre plastic can (see the illustration). This method avoids oil spillage. It also provides a more regular flow when filling.

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To check the oil levelTo check the oil levelTo check the oil levelTo check the oil level, see Oil level, checkingOil level, checkingOil level, checkingOil level, checking . Method 3Method 3Method 3Method 3 Push in the oil from the hydraulic pump. Note! Note! Note! Note! After changing the gearbox oil, the After changing the gearbox oil, the After changing the gearbox oil, the After changing the gearbox oil, the gearbox adaptation and the gearbox adaptation and the gearbox adaptation and the gearbox adaptation and the ““““Gearbox oil Gearbox oil Gearbox oil Gearbox oil changechangechangechange” ” ” ” counters must be reset. Use VIDA counters must be reset. Use VIDA counters must be reset. Use VIDA counters must be reset. Use VIDA vehicle communication to set the adaptation vehicle communication to set the adaptation vehicle communication to set the adaptation vehicle communication to set the adaptation and counters to zero.and counters to zero.and counters to zero.and counters to zero.

Check the coolant level in the expansion tankCheck the coolant level in the expansion tankCheck the coolant level in the expansion tankCheck the coolant level in the expansion tank

Top up with water and coolant as necessary (when the engine is at operating temperature). Raise the car. Check that there is no oil leakage at:

the connections for the oil pipes on the gearbox the side cover the side cover around the drive shaft.

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Installing the splash guards and the wing linerInstalling the splash guards and the wing linerInstalling the splash guards and the wing linerInstalling the splash guards and the wing liner

Install: The ABS-cable on the mounting the splash guard under the engine the front splash guard the nut for the left wing liner the wheels. See Installing wheelsInstalling wheelsInstalling wheelsInstalling wheels .

Lower the carLower the carLower the carLower the car

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Checking the steering gear bearing in the boot Checking the steering gear bearing in the boot Checking the steering gear bearing in the boot Checking the steering gear bearing in the boot at the bulkhead at the bulkhead at the bulkhead at the bulkhead Check the steering gear bearing in the boot at the bulkhead according to Transmission, Transmission, Transmission, Transmission, installinginstallinginstallinginstalling . Installing the battery leadInstalling the battery leadInstalling the battery leadInstalling the battery lead See Note when disconnecting/connecting the Note when disconnecting/connecting the Note when disconnecting/connecting the Note when disconnecting/connecting the battery leadbattery leadbattery leadbattery lead . It is essential that the instructions are followed. Test driving the carTest driving the carTest driving the carTest driving the car Note! Note! Note! Note! Test drive the car in the same way as Test drive the car in the same way as Test drive the car in the same way as Test drive the car in the same way as before the repair. See before the repair. See before the repair. See before the repair. See Gearbox checking/faultGearbox checking/faultGearbox checking/faultGearbox checking/fault----tracingtracingtracingtracing . . . . In the event of faults other than vibrations In the event of faults other than vibrations In the event of faults other than vibrations In the event of faults other than vibrations

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(judder)(judder)(judder)(judder) For information about test driving the car, see Test Drive Form, descriptionTest Drive Form, descriptionTest Drive Form, descriptionTest Drive Form, description . Note! Note! Note! Note! After changing the gearbox oil, the After changing the gearbox oil, the After changing the gearbox oil, the After changing the gearbox oil, the gearbox adaptation and the gearbox adaptation and the gearbox adaptation and the gearbox adaptation and the ““““Gearbox oil Gearbox oil Gearbox oil Gearbox oil changechangechangechange” ” ” ” counters must be reset. Use VIDA counters must be reset. Use VIDA counters must be reset. Use VIDA counters must be reset. Use VIDA vehicle communication to set the adaptation vehicle communication to set the adaptation vehicle communication to set the adaptation vehicle communication to set the adaptation and counters to zero.and counters to zero.and counters to zero.and counters to zero.

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s80 replace shift solenoid

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